Wing positioning system, wing positioning and monitoring method for holding state during processing

Abstract

The application discloses a wing posture adjusting positioning system and a holding state monitoring method in a wing posture adjusting and processing process, relates to the technical field of digital interfacing and assembling of airplane major parts, and comprises three or more three-coordinate numerical control positioners and a control system. A tension and pressure bidirectional force sensor is arranged on the three-coordinate numerical control positioner, a vacuum chuck assembly is arranged on the tension and pressure bidirectional force sensor, a vacuum degree sensor is arranged at the front end of the vacuum chuck assembly, a laser distance sensor is further arranged on the three-coordinate numerical control positioner, and the control system is connected with the tension and pressure bidirectional force sensor, the vacuum degree sensor and the laser distance sensor. The relative position relationship change condition between the wing and the numerical control positioner, the force value change condition between the wing and the process joint of the numerical control positioner and the pressure value change condition of the vacuum adsorption are detected in the wing posture adjusting and processing process, and the wing holding state is monitored in real time.

Description

Technical Field

[0001] This invention discloses a wing attitude adjustment and positioning system, a method for monitoring the holding state during wing attitude adjustment and processing, and relates to the field of digital docking and assembly technology for large aircraft components. Background Technology

[0002] In aircraft assembly, attitude adjustment of large wing components is often required to facilitate the mating of wing and fuselage components or the precision machining of wing mating surfaces. Traditional wing component attitude adjustment methods involve positioning the wing using specially designed clamps or jigs, and then manually adjusting the wing to the required position. This method is inefficient and cannot guarantee assembly quality.

[0003] To improve the automation and flexibility of aircraft assembly, various wing component attitude adjustment and positioning systems have been developed both domestically and internationally to achieve the holding and automated attitude adjustment of large wing components or wing panels. Chinese Patent CN107161355A, published on June 18, 2019, discloses a CNC positioner for aircraft wing panels. This CNC positioner includes a base, a column mounted on the base, and a telescopic column mounted on the column. The front end of the telescopic column is equipped with a mounting seat with a guide rail. The mounting seat is equipped with a ball joint positioning mechanism, and the bottom of the ball joint positioning mechanism is equipped with a slider that cooperates with the guide rail. A locking mechanism for fixing the position of the slider is also installed on the guide rail. Chinese Patent No. CN107471171A, published on March 1, 2022, discloses an assembly method for complex components on a large aircraft that integrates thermal deformation and gravity deformation. The attitude adjustment and positioning steps include: (1) discretizing the key features of the complex component and its three-dimensional model into a set of key feature points; (2) obtaining the coordinate values ​​of the key feature points on both; (3) calculating the coordinate deviation of the key feature points caused by temperature and gravity using a finite element analysis model based on the assembly environment temperature; (4) correcting the coordinate values ​​of the key feature points on the complex component based on the obtained coordinate deviation; and (5) calculating the pose coordination matrix T used to adjust and position the complex component to the target pose based on the corrected coordinate values ​​of the key feature points on the complex component and the coordinate values ​​of the key feature points on the three-dimensional model.

[0004] Existing attitude adjustment and positioning systems for large wing components or wing panels can achieve wing fixation and automated attitude adjustment, but they lack monitoring of the fixation status during the attitude adjustment or manufacturing process of large wing components or wing panels, which cannot effectively guarantee system safety. Summary of the Invention

[0005] This invention addresses the problems in existing technologies by proposing a wing attitude adjustment and positioning system, and a method for monitoring the hold-up state during wing attitude adjustment and machining. By detecting changes in the relative positional relationship between the wing and the CNC positioner during wing attitude adjustment and machining, changes in the force values ​​at the process joints between the wing and the CNC positioner, and changes in the pressure values ​​of vacuum adsorption, the wing's hold-up state is monitored in real time. This prevents problems such as poor attitude adjustment accuracy, wing slippage leading to machining errors, or safety accidents caused by ineffective hold-up during wing attitude adjustment and machining.

[0006] To achieve the above-mentioned objectives, the technical solution of the present invention is as follows: A wing attitude adjustment and positioning system includes three or more coordinate measuring machine (CNC) positioners and a control system. Each CNC positioner is equipped with a tension / compression bidirectional force sensor at its upper end, a vacuum suction cup assembly at its upper end, a vacuum degree sensor at its front end, and a laser distance sensor. The control system is connected to the tension / compression bidirectional force sensor, the vacuum degree sensor, and the laser distance sensor.

[0007] Preferably, the three-coordinate CNC positioner includes an X-axis, a Y-axis, and a Z-axis, with the Y-axis set on the X-axis and the Z-axis set on the Y-axis; or the X-axis set on the Y-axis and the Z-axis set on the Z-axis.

[0008] Preferably, the control system is used to realize the coordinated control of three or more coordinate measuring machine (CNC) positioners and to process multi-sensor data fusion; it also includes an independently set safety module to realize emergency stop logic control and communicate with the main control system through an EtherCAT network; each CNC positioner is configured with a local slave station and communicates with the master station through distributed I / O to reduce signal delay.

[0009] A method for monitoring the hold-up state during wing attitude adjustment and processing is disclosed. This method utilizes a wing attitude adjustment and positioning system, in which three or more coordinate-controlled positioners are arranged in an array to support and adsorb the wing. These positioners coordinate their movements to adjust the wing's six degrees of freedom spatial position and attitude. The hold-up state is monitored in real time during wing attitude adjustment and subsequent processing. Using multi-source sensor data and a hierarchical algorithm, real-time and accurate monitoring of the wing's adsorption, force, and attitude states is achieved, triggering different levels of safety response mechanisms accordingly.

[0010] Preferably, it includes the following steps: Step 1: Install a vacuum sensor, a tension / compression bidirectional force sensor, and a laser distance sensor in the three-coordinate CNC positioner, and connect the detection signals to the control system to achieve integrated control; Step 2: Arrange the three-axis CNC positioner according to the wing shape characteristics; Step 3: Initialize the control system, complete sensor calibration and parameter loading. After initialization, mount the wing and run algorithms A1 and A2 in real time to monitor vacuum adsorption and support force uniformity, guiding the adjustment of each axis position and support height of each three-axis CNC positioner until all values ​​meet the standards. At this point, the system effectively holds the wing. After the state stabilizes, perform "attitude calibration" and record all data. for ; Step 4: Execute the following steps repeatedly while in posture adjustment or processing mode: Collect all sensor data , , ;in, The negative pressure value for each vacuum suction cup assembly; The force exerted on each vacuum suction cup assembly; The distance from each measuring point to its mounting reference surface; Run Algorithm A1: Update Adsorption_Status_i; Run Algorithm A2: Calculate and Update Force_status_i; Run Algorithm A3: Calculate , , , , , , ; Run Algorithm A4: Perform data association analysis; System status assessment and response decision-making: The control system conducts a comprehensive evaluation in real time based on the results of the A1-A4 algorithm and triggers different levels of response actions: system operation interface prompts, audible and visual alarms, program pause, emergency stop commands, etc., while simultaneously recording all data and events. Step 5: Complete the wing attitude adjustment and processing procedures, and remove the wing from the assembly line.

[0011] Preferably, in step three, guiding the adjustment of the axis positions and support heights of each coordinate measuring machine positioner includes: Vacuum Adsorption State Adjustment: Run Algorithm A1 to monitor the effectiveness of the vacuum adsorption state of each CNC positioner. If the negative pressure value of the vacuum suction cup assembly i of a certain CNC positioner is... >Safety threshold This indicates that the vacuum suction cup assembly of the three-coordinate CNC positioner has adhered to the wing surface, forming an effective suction; if the negative pressure value of the vacuum suction cup assembly i of a certain three-coordinate CNC positioner is... <Safety threshold This indicates that the vacuum suction cup assembly of the CNC positioner is not in contact with the wing surface. Check the contact status between the vacuum suction cup assembly and the wing surface, and adjust the three axes of the CNC positioner according to the gap between them until... > At this point, effective adsorption is formed; check the negative pressure value of each coordinate measuring machine positioner in sequence using this method until the adsorption state of all coordinate measuring machine positioners meets the requirements. Support force adjustment: Run algorithm A2 to monitor the effectiveness and uniformity of support for each CNC positioner, ensuring reliable support. If the standard deviation of the support force of the CNC positioner is... > The adjustment amount of the CNC positioner is automatically generated by the control system; Z-axis adjustment amount: k is the stiffness coefficient, determined by test; the X-axis / Y-axis must not be adjusted in this state to prevent wing slippage due to vacuum adsorption failure; if the support force still cannot meet the requirements after this adjustment, the mounting position does not meet the requirements and needs to be readjusted.

[0012] Preferably, the algorithm A1 - vacuum adsorption status judgment: for each vacuum suction cup component i: if the negative pressure value is lower than the safety threshold, Adsorption_Status_i is updated to "vacuum adsorption of vacuum suction cup component i has failed"; if the negative pressure value is not lower than the safety threshold, Adsorption_Status_i is updated to "vacuum adsorption of vacuum suction cup component i is effective".

[0013] Preferably, the algorithm A2-threshold comparison and rate of change analysis: A21. Support uniformity during the shelving stage: Calculate all Standard deviation , and the preset uniformity threshold In comparison, if the position is within the range, the CNC positioner can effectively support the wing; otherwise, uniform support is not formed, and the CNC positioner or wing attitude needs to be readjusted, or even remounted. A22. Full-process abnormal force detection: For each three-axis CNC positioner i, if the absolute value exceeds the limit: The absolute value is greater than The absolute value, when When the value is negative, Force_status_i = "Force value of CNC positioner i exceeds limit". When the value is negative, Force_status_i = "Pressure value of coordinate NC positioner i exceeds limit"; For each three-axis CNC positioner i whose rate of change exceeds the limit: ;in, This represents the rate of change of force value within a certain time period t. Indicates the current force value. This represents the initial force value, and t represents the sampling time period. The absolute value is greater than The absolute value, The set force change rate threshold is indicated; Force_status_i is updated to "CNC positioner i force change rate exceeds limit"; if The absolute value is not greater than The absolute value of Force_status_i is updated to "Numerical positioner i force value change rate is normal".

[0014] Preferably, the algorithm A3-spatial geometry calculation establishes a baseline: the distance collected after the wing is mounted and under normal uniform support. Set as , representing the initial attitude; real-time calculation: single-point displacement calculation: Overall attitude calculation: Input: Known spatial coordinates of all measurement points ( and corresponding Processing: The current wing attitude is calculated in real time using a rigid body kinematics model. Output: Average buoyancy, Roll angle about the X-axis Pitch angle around the Y-axis : Rate of change of roll angle Rate of change of pitch angle : Rate of change of average buoyancy; For the average buoyancy: Assuming there are n three-axis CNC positioners, then ; , The attitude angles of the wing around the X and Y axes are calculated using spatial geometric fitting or plane fitting algorithms based on the spatial coordinate layout and distance changes of each three-coordinate CNC positioner.

[0015] , Rate of change of attitude angle: For the calculated attitude angle , Differentiate with respect to time t, or calculate the ratio of the attitude angle difference between adjacent sampling periods to the time interval: ; ; The calculated average buoyancy Take the derivative with respect to time t, or calculate the difference between adjacent sampling periods: .

[0016] Preferably, the algorithm A4-logic judgment: when a vacuum suction cup component Adsorption_Status_i = "vacuum suction cup component i vacuum adsorption failure", closely monitor the corresponding position. and ,like Rapidly increasing and If the direction of the pulling force changes, the probability of the wing slipping due to the failure of vacuum adsorption at that point is extremely high.

[0017] Preferably, the response includes level 0 (normal level), level 1 (early warning level), level 2 (alarm level), and level 3 (emergency shutdown level).

[0018] Preferably, level 0 (normal level) means: normal operation: all states are within the safety threshold; response: normal operation.

[0019] Preferably, Level 1 (early warning level): Status warning: Adsorption_Status_i of a single vacuum suction cup component fluctuates briefly but remains above the minimum threshold; single force or rate of change of force Approaching the threshold but not exceeding it; single Approaching the single-point displacement threshold; attitude parameters , , Approaching the threshold; Response: Highlight the abnormal point / parameter on the control system's display interface, emit an audible and visual alert (distinct from an alarm sound), and record the current log. Operator intervention is required. The control system can continue to operate, but vigilance must be maintained, and the system's operating status must be continuously observed.

[0020] Preferably, level 2 (alarm level): Status alarm: The Adsorption_Status_i of a single vacuum suction cup component remains "vacuum suction cup component i vacuum adsorption failure"; Single force or rate of change of force Exceeding the set threshold; a single Exceeding the single-point displacement threshold; attitude parameters , , If the threshold is exceeded; Response: The control system issues an audible and visual alarm, clearly indicates the fault point / type and the value of the parameter exceeding the limit on the control system's display interface, and automatically pauses the current automatic posture adjustment or machining program, waiting for operator confirmation. The operator needs to formulate a solution based on the situation.

[0021] Preferably, Level 3 (Emergency Stop Level): Adsorption failure: Multiple vacuum suction cup components simultaneously display "Vacuum suction cup component i vacuum adsorption failure"; Abnormal force: Multiple tension and compression bidirectional force sensors simultaneously exceed limits or a single force far exceeds the threshold or A sharp increase indicates that the bidirectional force sensor has detected a severe impact force; attitude instability: attitude parameters , , Significantly exceeding the threshold or its rate of change , Exceeding the preset emergency threshold indicates that the wing is rapidly sliding or overturning; High correlation risk: Algorithm A4 determines that adsorption failure leads to rapid changes in displacement and abnormal force; Response: Triggers the highest level, urgent audible and visual alarm, the control system immediately sends an emergency stop message to all actuators, the attitude adjustment mechanism stops moving, the machining equipment spindle stops rotating and retracts the tool. This response has the highest priority and cannot be blocked by software logic to ensure physical isolation of the risk source.

[0022] The beneficial effects of this invention are: I. This invention provides a method for monitoring the hold-up state during wing attitude adjustment and manufacturing processes, constructing a progressive multi-level safety protection mechanism from "early warning - alarm - emergency shutdown". The early warning level provides opportunities for early intervention, reducing unnecessary shutdowns; the alarm level prevents the state from deteriorating; and the emergency shutdown level provides the highest level of safety assurance in extreme situations, maximizing the protection of personnel and equipment safety.

[0023] II. This invention provides a method for monitoring the hold-up state during wing attitude adjustment and manufacturing processes, achieving algorithm-driven precise monitoring. The spatial geometry algorithm A3 transforms discrete displacement point data into intuitive, global attitude parameters, enabling a quantitative assessment of wing hold-up stability. Monitoring the rate of change of force and support distance (A2 algorithm) significantly improves the sensitivity to detecting sudden and rapidly evolving risks. Data correlation analysis A4 improves the diagnostic accuracy for complex failure modes, reducing false alarms and missed alarms.

[0024] Third, the present invention provides a method for monitoring the hold-up state during wing attitude adjustment and manufacturing processes, which improves the automation and intelligence of abnormal response to wing hold-up states. Based on algorithm-based state assessment, it automatically triggers preset response levels, reducing delays and errors caused by human judgment, resulting in more timely and reliable responses. In particular, the automatic execution of emergency stop commands is a key guarantee for safety.

[0025] IV. The present invention provides a method for monitoring the hold-up state during wing attitude adjustment and processing, which improves the reliability of the wing attitude adjustment and processing system. Through the combined effects of multi-sensor redundancy, multi-algorithm cross-validation, and a multi-level response mechanism, the reliability of the entire system is greatly enhanced.

[0026] V. The present invention provides a method for monitoring the hold-up state during wing attitude adjustment and processing, which improves the quality of wing processing. By monitoring the uniformity of support force in real time, deformation of the wing panel caused by excessive local support force is avoided, ensuring structural stability during processing and thus improving the processing accuracy of drilling, riveting, and other processes.

[0027] VI. The present invention provides a method for monitoring the holding state during wing attitude adjustment and processing, which can effectively extend the equipment life. Through abnormal force detection (algorithm A2), overload of the three-coordinate CNC positioner caused by mechanical interference or misoperation can be detected and prevented in a timely manner, protecting precision mechanical parts and vacuum suction cup assemblies from damage.

[0028] VII. The present invention provides a method for monitoring the holding state during wing attitude adjustment and processing, which can improve the production efficiency of wing attitude adjustment and processing. By automatically guiding the adjustment of the three-coordinate CNC positioner through an algorithm, it replaces the traditional manual adjustment method based on experience and repeated trial and error, significantly shortening the preparation time for wing mounting and attitude adjustment. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the wing attitude adjustment and positioning system in this invention; Figure 2 This is a schematic diagram of the three-coordinate numerical control positioner in this invention; The components include: 1. Wing; 2. Three-coordinate CNC positioner; 3. Vacuum sensor; 4. Control system; 5. Vacuum suction cup assembly; 6. Tension and compression bidirectional force sensor; 7. Laser distance sensor. Detailed Implementation

[0030] The present invention will be further described in detail below with reference to embodiments, but the implementation of the present invention is not limited thereto.

[0031] Example 1 like Figure 1 and Figure 2As shown, an airfoil attitude adjustment and positioning system includes three or more coordinate-controlled positioners 2 and a control system 4. The upper end of each coordinate-controlled positioner 2 is provided with a tension and compression bidirectional force sensor 6. The upper end of each tension and compression bidirectional force sensor 6 is provided with a vacuum suction cup assembly 5. The front end of the vacuum suction cup assembly 5 is provided with a vacuum degree sensor 3. The coordinate-controlled positioner 2 is also provided with a laser distance sensor 7. The control system 4 is connected to the tension and compression bidirectional force sensor 6, the vacuum degree sensor 3 and the laser distance sensor 7.

[0032] The three-coordinate CNC positioner 2 includes an X-axis, a Y-axis, and a Z-axis. The Y-axis is set on the X-axis, and the Z-axis is set on the Y-axis; or the X-axis is set on the Y-axis, and the Z-axis is set on the Z-axis.

[0033] In the three-coordinate CNC positioner 2, the X, Y, and Z axes are orthogonal to each other. All three axes are driven by high-precision servo motors, and a linear encoder is used to achieve full closed-loop control to compensate for mechanical errors. For the horizontal movement mechanism (generally the X and Y axes), a precision ball screw or rack and pinion gear + reducer transmission is used, with linear guide rails for guidance. For the vertical movement mechanism (generally the Z axis), a precision ball screw + worm gear reducer transmission is used to prevent accidental falls, with linear guide rails for guidance.

[0034] The control system 4 is used to realize the coordinated control of three or more coordinate caliber positioners 2 and to process multi-sensor data fusion; it also includes an independently set safety module to realize emergency stop logic control and communicate with the main control system 4 through the EtherCAT network; each coordinate caliber positioner 2 is configured with a local slave station and communicates with the master station through distributed I / O to reduce signal delay.

[0035] The main control unit of the control system 4 uses an industrial-grade computer as its platform. It achieves coordinated control of multiple CNC positioners through an existing mature multi-axis control system. The computer runs a real-time kernel to process multi-sensor data fusion. An independently configured safety module implements emergency stop logic control and communicates with the main control system 4 via an EtherCAT network. Each three-axis CNC positioner 2 is configured with a local slave station, communicating with the master station through distributed I / O to reduce signal delay.

[0036] The wing attitude adjustment and positioning system supports and adsorbs the wing 1 through three or more three-coordinate CNC positioners 2 with vacuum suction cup components 5 at the end, achieving a holding effect. Through the coordinated movement of the three-coordinate CNC positioners 2, the six-degree-of-freedom attitude adjustment of the wing 1 is realized, which enables subsequent assembly, processing and other processes.

[0037] The vacuum suction cup assembly 5 of the three-coordinate CNC positioner 2 is equipped with a vacuum sensor 3 at its front end, which can detect the negative pressure value of the vacuum suction cup assembly 5. When the vacuum system is working and the negative pressure value is zero, the vacuum suction cup assembly 5 does not adsorb. When the wing 1 is mounted, the vacuum suction cup assembly 5 and the lower surface of the wing are tightly attached to form an effective adsorption. The vacuum sensor 3 detects that the negative pressure value reaches the set threshold, and the three-coordinate CNC positioner 2 effectively adsorbs the wing 1. The vacuum sensor 3 can transmit the vacuum value to the system in real time.

[0038] The vacuum suction cup assembly 5 of the three-coordinate CNC positioner 2 is equipped with a two-way force sensor 6 for tension and compression, which can detect the tension force on the wing 1 in real time.

[0039] A laser distance sensor 7 is installed inside or near the vacuum suction cup assembly 5 of the three-coordinate CNC positioner 2 at a safe position that is relatively stationary relative to the vacuum suction cup assembly 5. The laser distance sensor 7 detects the relative distance between the wing 1 and the three-coordinate CNC positioner 2 in real time.

[0040] Example 2 A method for monitoring the hold-up state during wing attitude adjustment and processing is disclosed. This method utilizes a wing attitude adjustment and positioning system, in which three or more coordinate-controlled positioners 2 are arranged in an array to support and adsorb the wing 1. The coordinated movement of these three or more positioners allows for the adjustment of the wing 1's six-degree-of-freedom spatial position and attitude. Real-time monitoring of the hold-up state during wing attitude adjustment and subsequent processing is achieved using multi-source sensor data and hierarchical algorithm processing. This enables real-time and precise monitoring of the wing 1's adsorption, force, and attitude states, triggering different levels of safety response mechanisms accordingly.

[0041] Example 3 A method for monitoring the hold-up state during wing attitude adjustment and processing is disclosed. This method utilizes a wing attitude adjustment and positioning system, in which three or more coordinate-controlled positioners 2 are arranged in an array to support and adsorb the wing 1. The coordinated movement of these three or more positioners allows for the adjustment of the wing 1's six-degree-of-freedom spatial position and attitude. Real-time monitoring of the hold-up state during wing attitude adjustment and subsequent processing is achieved using multi-source sensor data and hierarchical algorithm processing. This enables real-time and precise monitoring of the wing 1's adsorption, force, and attitude states, triggering different levels of safety response mechanisms accordingly.

[0042] This includes the following steps: Step 1: Install a vacuum sensor 3, a bidirectional force sensor 6 (tension and compression), and a laser distance sensor 7 in the three-coordinate CNC positioner 2, and connect the detection signals to the control system 4 to achieve integrated control; Step 2: Arrange the three-axis CNC positioner 2 according to the shape characteristics of wing 1; Step 3: Initialize the control system 4, complete sensor calibration and parameter loading. After initialization, mount wing 1 and run algorithms A1 and A2 in real time to monitor vacuum adsorption and support force uniformity, guiding the adjustment of each axis position and support height of the three-axis CNC positioners 2 until all values ​​meet the standards. At this point, it indicates that the system effectively holds wing 1. After the state stabilizes, perform "attitude calibration" and record all data. for ; Step 4: Execute the following steps repeatedly while in posture adjustment or processing mode: Collect all sensor data , , ;in, The negative pressure value for each vacuum suction cup assembly 5; The force exerted on each vacuum suction cup assembly 5; The distance from each measuring point to its mounting reference surface; Run Algorithm A1: Update Adsorption_Status_i; Run Algorithm A2: Calculate and Update Force_status_i; Run Algorithm A3: Calculate , , , , , , ; Run Algorithm A4: Perform data association analysis; System status assessment and response decision-making: The control system 4 conducts a real-time comprehensive assessment based on the results of the A1-A4 algorithm and triggers different levels of response actions: system operation interface prompts, audible and visual alarms, program pause, emergency stop commands, etc., while simultaneously recording all data and events. Step 5: Complete the attitude adjustment and processing of wing 1, and remove wing 1 from the assembly line.

[0043] In step three, guiding the adjustment of the axis positions and support heights of each of the three-axis CNC positioners 2 includes: Vacuum adsorption state adjustment: Run algorithm A1 to monitor whether the vacuum adsorption state of each CNC positioner 2 is effective. If the negative pressure value of the vacuum suction cup assembly 5i of a certain CNC positioner 2 is... >Safety threshold This indicates that the vacuum suction cup assembly 5 of the three-coordinate CNC positioner 2 has adhered to the surface of the wing 1, forming an effective adsorption; if the negative pressure value of the vacuum suction cup assembly 5i of a certain three-coordinate CNC positioner 2 is... <Safety threshold This indicates that the vacuum suction cup assembly 5 of the three-axis CNC positioner 2 is not in contact with the surface of the wing 1. Check the contact status between the vacuum suction cup assembly 5 and the surface of the wing 1, and adjust the three axes of the three-axis CNC positioner 2 according to the gap between them until... > At this point, effective adsorption is formed; the negative pressure value of each three-axis CNC positioner 2 is checked in turn using this method until the adsorption state of all three-axis CNC positioners 2 meets the requirements; Support force adjustment: Run algorithm A2 to monitor the effectiveness and uniformity of support for each CNC positioner 2 pair, ensuring reliable support. If the standard deviation of the support force of the CNC positioner 2 is... > The adjustment amount of the three-coordinate CNC positioner 2 is automatically generated by the control system 4; Z-axis adjustment amount: k is the stiffness coefficient, determined by test; the X-axis / Y-axis must not be adjusted in this state to prevent wing slippage due to vacuum adsorption failure; if the support force still cannot meet the requirements after this adjustment, the mounting position does not meet the requirements and needs to be readjusted.

[0044] The algorithm A1-vacuum adsorption status judgment is as follows: For each vacuum suction cup component 5i: if the negative pressure value is lower than the safety threshold, Adsorption_Status_i is updated to "vacuum adsorption of vacuum suction cup component 5i has failed"; if the negative pressure value is not lower than the safety threshold, Adsorption_Status_i is updated to "vacuum adsorption of vacuum suction cup component 5i is effective".

[0045] Among them, the algorithm A2-threshold comparison and rate of change analysis: A21. Support uniformity during the shelving stage: Calculate all The standard deviation or the difference between the maximum and minimum values, compared with the preset uniformity threshold. In comparison, if it is within the range, the CNC positioner can effectively support wing 1; otherwise, it does not form uniform support and the CNC positioner or the wing 1 position needs to be readjusted, or even remounted. A22. Full-process abnormal force detection: For each three-axis CNC positioner 2i, the absolute value exceeds the limit: if The absolute value is greater than The absolute value, when When the value is negative, Force_status_i = "Force value of CNC positioner 2 i exceeds limit". When the value is negative, Force_status_i = "Pressure value of coordinate NC positioner 2 i exceeds limit"; For each three-axis CNC positioner 2i, the rate of change exceeds the limit: ;in, This represents the rate of change of force value within a certain time period t. Indicates the current force value. This represents the initial force value, and t represents the sampling time period. The absolute value is greater than The absolute value, This indicates the set threshold for the rate of change of force value; Force_status_i is updated to "Force value change rate of change of three-axis CNC positioner 2 i exceeds the limit"; if The absolute value is not greater than The absolute value of Force_status_i is updated to "The force value change rate of the three-coordinate CNC positioner 2 is normal".

[0046] Among them, the algorithm A3 - spatial geometry calculation: establish a benchmark: after wing 1 is mounted, it is under normal and uniform support, and the distance collected is... Set as , representing the initial attitude; real-time calculation: single-point displacement calculation: Overall attitude calculation: Input: Known spatial coordinates of all measurement points ( ) and corresponding Processing: The current attitude of wing 1 is calculated in real time using a rigid body kinematics model. Output: Average buoyancy, Roll angle about the X-axis Pitch angle around the Y-axis : Rate of change of roll angle Rate of change of pitch angle : Rate of change of average buoyancy; For the average buoyancy: Assuming there are n three-axis CNC positioners 2, then ; , The attitude angles of the wing around the X and Y axes are calculated based on the spatial coordinate layout and distance changes of each three-coordinate CNC positioner 2, using spatial geometric fitting or plane fitting algorithms.

[0047] For example, if the three-axis CNC positioners 2 are arranged in a rectangular pattern, the tilt angle can be approximated by dividing the distance difference between the diagonal position sensors by the span. Accurate calculations typically employ the least squares method to fit the plane equation Ax + By + Cz + D = 0, and then calculate based on the plane normal vector. , .

[0048] , Rate of change of attitude angle: For the calculated attitude angle , Differentiate with respect to time t, or calculate the ratio of the attitude angle difference between adjacent sampling periods to the time interval: ; ; The calculated average buoyancy Take the derivative with respect to time t, or calculate the difference between adjacent sampling periods: .

[0049] : #Assume at least 3 non-collinear measuring points are set up. #Construct equations to solve for attitude changes

[0050] # #A: Coefficient matrix (composed of the X and Y coordinates of the measurement points); b: Observation vector

[0051] x: Vector to be determined ( , ) x = least_squares_solve(A, b) # Solve using least squares

[0052] #t represents time, converted to angles #t represents time, converted to angles Specifically, the A4 logic judgment states that when a vacuum suction cup component Adsorption_Status_i = "vacuum suction cup component i vacuum adsorption failure", the corresponding position is closely monitored. and ,like Rapidly increasing and If the direction of the pulling force changes, the probability of the wing slipping due to the failure of vacuum adsorption at that point is extremely high.

[0053] The response includes level 0 (normal level), level 1 (early warning level), level 2 (alarm level), and level 3 (emergency shutdown level).

[0054] Among them, level 0 (normal level): normal operation: all states are within the safety threshold; response: normal operation.

[0055] Among them, Level 1 (Warning Level): Status Warning: A single vacuum suction cup assembly 5 Adsorption_Status_i experiences brief fluctuations but remains above the minimum threshold; a single force or rate of change of force Approaching the threshold but not exceeding it; single Approaching the single-point displacement threshold; attitude parameters , , Approaching the threshold; Response: The abnormal point / parameter is highlighted on the display interface of the control system 4, an audible and visual prompt is emitted, and this sound is different from the alarm sound. The current log is recorded, and the operator intervenes to check. The control system 4 can continue to operate, but vigilance must be maintained to continuously observe the system's working status.

[0056] Among them, Level 2 (Alarm Level): Status Alarm: The Adsorption_Status_i of a single vacuum suction cup assembly 5 remains "Vacuum suction cup assembly 5 i vacuum adsorption failure"; Single force or rate of change of force Exceeding the set threshold; a single Exceeding the single-point displacement threshold; attitude parameters , , If the threshold is exceeded; Response: The control system 4 issues an audible and visual alarm, clearly indicating the fault point / type and the value of the parameter exceeding the limit on the display interface of the control system 4. The control system 4 automatically pauses the current automatic posture adjustment or machining program and waits for operator confirmation. The operator needs to formulate a solution based on the situation.

[0057] Among them, Level 3 (Emergency Stop Level): Adsorption failure: Multiple vacuum suction cup components 5 simultaneously show "Vacuum suction cup component 5 i vacuum adsorption failure"; Abnormal force: Multiple tension and compression bidirectional force sensors 6 simultaneously exceed limits or a single force far exceeds the threshold or A sharp increase indicates that the bidirectional force sensor 6 has detected a severe impact force; attitude instability: attitude parameters , , Significantly exceeding the threshold or its rate of change , If the preset emergency threshold is exceeded, it indicates that wing 1 is rapidly sliding or overturning; High correlation risk: Algorithm A4 determines that the adsorption failure leads to rapid changes in displacement and abnormal force; Response: Trigger the highest level, urgent audible and visual alarm, control system 4 immediately sends an emergency stop message to all actuators, the attitude adjustment mechanism stops moving, the machining equipment spindle stops rotating and retracts the tool. This response has the highest priority and cannot be blocked by software logic to ensure physical isolation of the risk source.

[0058] The beneficial effects of this invention are: I. This invention provides a method for monitoring the hold-up state during wing attitude adjustment and manufacturing processes, constructing a progressive multi-level safety protection mechanism from "early warning - alarm - emergency shutdown". The early warning level provides opportunities for early intervention, reducing unnecessary shutdowns; the alarm level prevents the state from deteriorating; and the emergency shutdown level provides the highest level of safety assurance in extreme situations, maximizing the protection of personnel and equipment safety.

[0059] II. This invention provides a method for monitoring the hold-up state during wing attitude adjustment and manufacturing processes, achieving algorithm-driven precise monitoring. The spatial geometry algorithm A3 transforms discrete displacement point data into intuitive, global attitude parameters, enabling a quantitative assessment of the hold-up stability of wing 1. Monitoring the rate of change of force and support distance (A2 algorithm) significantly improves the detection sensitivity for sudden and rapidly evolving risks. Data correlation analysis A4 improves the diagnostic accuracy for complex failure modes, reducing false alarms and missed alarms.

[0060] Third, the present invention provides a method for monitoring the hold-up state during wing attitude adjustment and processing, which improves the automation and intelligence of abnormal response to the hold-up state of wing 1. Based on algorithm-based state assessment, it automatically triggers preset response levels, reducing delays and errors caused by human judgment, resulting in more timely and reliable responses. In particular, the automatic execution of emergency stop commands is a key guarantee for safety.

[0061] IV. The present invention provides a method for monitoring the hold-up state during wing attitude adjustment and processing, which improves the reliability of the wing attitude adjustment and processing system. Through the combined effects of multi-sensor redundancy, multi-algorithm cross-validation, and a multi-level response mechanism, the reliability of the entire system is greatly enhanced.

[0062] V. The present invention provides a method for monitoring the hold-up state during wing attitude adjustment and processing, which improves the processing quality of wing 1. By monitoring the uniformity of support force in real time, deformation of the wing panel caused by excessive local support force is avoided, ensuring structural stability during processing, thereby improving the processing accuracy of drilling, riveting, and other processes.

[0063] VI. The present invention provides a method for monitoring the holding state during wing attitude adjustment and processing, which can effectively extend the equipment life. Through abnormal force detection (algorithm A2), overload of the three-coordinate CNC positioner 2 caused by mechanical interference or misoperation can be detected and prevented in a timely manner, protecting precision mechanical parts and vacuum suction cup assembly 5 from damage.

[0064] VII. The present invention provides a method for monitoring the holding state during wing attitude adjustment and processing, which can improve the production efficiency of wing attitude adjustment and processing. By automatically guiding the adjustment of the position of the three-coordinate CNC positioner 2 through an algorithm, it replaces the traditional manual adjustment method based on experience and repeated trial and error, significantly shortening the preparation time for wing mounting and attitude adjustment.

[0065] It is understood that the present invention has been described through some embodiments, and those skilled in the art will recognize that various changes or equivalent substitutions can be made to these features and embodiments without departing from the spirit and scope of the invention. Furthermore, under the teachings of the present invention, these features and embodiments can be modified to adapt to specific situations and materials without departing from the spirit and scope of the invention. Therefore, the present invention is not limited to the specific embodiments disclosed herein, and all embodiments falling within the scope of the claims of this application are within the protection scope of the present invention.

Claims

1. A wing attitude adjustment and positioning system, characterized in that: The system includes three or more coordinate measuring machine (CNC) positioners and a control system. Each CNC positioner is equipped with a tension / compression bidirectional force sensor at its upper end. Each tension / compression bidirectional force sensor is equipped with a vacuum suction cup assembly at its upper end. The vacuum suction cup assembly is equipped with a vacuum degree sensor at its front end. Each CNC positioner is also equipped with a laser distance sensor. The control system is connected to the tension / compression bidirectional force sensor, the vacuum degree sensor, and the laser distance sensor.

2. The wing attitude adjustment and positioning system according to claim 1, characterized in that: The three-coordinate CNC positioner includes an X-axis, a Y-axis, and a Z-axis, with the Y-axis set on the X-axis and the Z-axis set on the Y-axis.

3. The wing attitude adjustment and positioning system according to claim 2, characterized in that: The control system is used to achieve coordinated control of three or more coordinate measuring machine (CNC) positioners and to process multi-sensor data fusion; it also includes an independently set safety module to realize emergency stop logic control and communicate with the main control system through an EtherCAT network; each CNC positioner is configured with a local slave station and communicates with the master station through distributed I / O to reduce signal delay.

4. A method for monitoring the hold-up state during wing attitude adjustment and processing, characterized in that, Using the wing attitude adjustment and positioning system described in any one of claims 1-3, three or more coordinate-controlled positioners are arranged in an array to support and adsorb the wing. The three or more coordinate-controlled positioners move in coordination to adjust the wing's six degrees of freedom spatial position and attitude. The holding state is monitored in real time during the wing attitude adjustment process and during the processing after the attitude adjustment is completed. Using multi-source sensor data and through hierarchical algorithm processing, real-time and accurate monitoring of the wing's adsorption, force, and attitude state is achieved, and different levels of safety response mechanisms are triggered accordingly.

5. The method for monitoring the hold-up state during wing attitude adjustment and processing according to claim 4, characterized in that, Includes the following steps: Step 1: Install a vacuum sensor, a tension / compression bidirectional force sensor, and a laser distance sensor in the three-coordinate CNC positioner, and connect the detection signals to the control system to achieve integrated control; Step 2: Arrange the three-axis CNC positioner according to the wing shape characteristics; Step 3: Initialize the control system, complete sensor calibration and parameter loading. After initialization, mount the wing and run algorithms A1 and A2 in real time to monitor vacuum adsorption and support force uniformity, guiding the adjustment of each axis position and support height of each three-axis CNC positioner until all values ​​meet the standards. At this point, the system effectively holds the wing. After the state stabilizes, perform "attitude calibration" and record all data. for ; Step 4: Execute the following steps repeatedly while in posture adjustment or processing mode: Collect all sensor data , , ;in, The negative pressure value for each vacuum suction cup assembly; The force exerted on each vacuum suction cup assembly; The distance from each measuring point to its mounting reference surface; Run Algorithm A1: Update Adsorption_Status_i; Run Algorithm A2: Calculate and Update Force_status_i; Run Algorithm A3: Calculate , , , , , , ; Run Algorithm A4: Perform data association analysis; System status assessment and response decision-making: The control system conducts a comprehensive evaluation in real time based on the results of the A1-A4 algorithm and triggers different levels of response actions: system operation interface prompts, audible and visual alarms, program pause, emergency stop commands, etc., while simultaneously recording all data and events. Step 5: Complete the wing attitude adjustment and processing procedures, and remove the wing from the assembly line.

6. The method for monitoring the hold-up state during wing attitude adjustment and processing according to claim 5, characterized in that: In step three, guiding the adjustment of the axis positions and support heights of each coordinate measuring machine positioner includes: Vacuum adsorption state adjustment: Run algorithm A1 to monitor whether the vacuum adsorption state of each CNC positioner is effective. If the negative pressure value of the vacuum suction cup component i of a certain CNC positioner is... >Safety threshold This indicates that the vacuum suction cup assembly of the CNC positioner has adhered to the wing surface, forming an effective suction; if the negative pressure value of the vacuum suction cup assembly i of a certain CNC positioner... <Safety threshold This indicates that the vacuum suction cup assembly of the CNC positioner is not in contact with the wing surface. Check the contact status between the vacuum suction cup assembly and the wing surface, and adjust the three axes of the CNC positioner according to the gap between them until... > At this point, effective adsorption is formed; check the negative pressure value of each coordinate measuring machine positioner in sequence using this method until the adsorption state of all coordinate measuring machine positioners meets the requirements. Support force adjustment: Run algorithm A2 to monitor the effectiveness and uniformity of support for each CNC positioner, ensuring reliable support. If the standard deviation of the support force of the CNC positioner is... > The adjustment amount of the CNC positioner is automatically generated by the control system; Z-axis adjustment amount: k is the stiffness coefficient, determined by test; the X-axis / Y-axis must not be adjusted in this state to prevent wing slippage due to vacuum adsorption failure; if the support force still cannot meet the requirements after this adjustment, the mounting position does not meet the requirements and needs to be readjusted.

7. The method for monitoring the hold-up state during wing attitude adjustment and processing according to claim 6, characterized in that: The algorithm A1 - Vacuum Adsorption Status Judgment: For each vacuum suction cup component i: if the negative pressure value is lower than the safety threshold, Adsorption_Status_i is updated to "vacuum suction cup component i fails to adsorb vacuum"; if the negative pressure value is not lower than the safety threshold, Adsorption_Status_i is updated to "vacuum suction cup component i is effective in adsorbing vacuum".

8. The method for monitoring the hold-up state during wing attitude adjustment and processing according to claim 7, characterized in that: The algorithm A2-threshold comparison and rate of change analysis: A21. Support uniformity during the shelving stage: Calculate all Standard deviation , and the preset uniformity threshold In comparison, if the position is within the range, the CNC positioner can effectively support the wing; otherwise, uniform support is not formed, and the CNC positioner or wing attitude needs to be readjusted, or even remounted. A22. Full-process abnormal force detection: For each three-axis CNC positioner i, if the absolute value exceeds the limit: The absolute value is greater than The absolute value, when When the value is negative, Force_status_i = "Force value of the three-axis CNC positioner i exceeds the limit". When the value is negative, Force_status_i = "Pressure value of coordinate NC positioner i exceeds limit"; For each three-axis CNC positioner i whose rate of change exceeds the limit: ;in, This represents the rate of change of force value within a certain time period t. Indicates the current force value. This represents the initial force value, and t represents the sampling time period. The absolute value is greater than The absolute value, The set force change rate threshold is indicated; Force_status_i is updated to "CNC positioner i force change rate exceeds limit"; if The absolute value is not greater than The absolute value of Force_status_i is updated to "Numerical positioner i force value change rate is normal".

9. The method for monitoring the hold-up state during wing attitude adjustment and processing according to claim 8, characterized in that: Algorithm A3 - Spatial Geometry Calculation: Establishing a baseline: After the wing is mounted and under normal, uniform support, the distance collected is... Set as , representing the initial attitude; real-time calculation: single-point displacement calculation: ; Overall attitude calculation: Input: Known spatial coordinates of all measurement points ( and corresponding Processing: The current wing attitude is calculated in real time using a rigid body kinematics model. Output: Average buoyancy, Roll angle about the X-axis Pitch angle around the Y-axis : Rate of change of roll angle Rate of change of pitch angle : Rate of change of average buoyancy; For the average buoyancy: Assuming there are n three-axis CNC positioners, then ; , The attitude angles of the wing around the X and Y axes are calculated using spatial geometric fitting or plane fitting algorithms based on the spatial coordinate layout and distance changes of each three-coordinate CNC positioner. , Rate of change of attitude angle: For the calculated attitude angle , Differentiate with respect to time t, or calculate the ratio of the attitude angle difference between adjacent sampling periods to the time interval: ； ； The calculated average buoyancy Take the derivative with respect to time t, or calculate the difference between adjacent sampling periods: 。 10. The method for monitoring the hold-up state during wing attitude adjustment and processing according to claim 9, characterized in that: The algorithm A4-logic judgment: When a vacuum suction cup component Adsorption_Status_i = "vacuum suction cup component i vacuum adsorption failure", closely monitor the corresponding position. and ,like Rapidly increasing and If the direction of the pulling force changes, the probability of the wing slipping due to the failure of vacuum adsorption at that point is extremely high.

11. The method for monitoring the hold-up state during wing attitude adjustment and processing according to claim 10, characterized in that: The response includes level 0 (normal level), level 1 (early warning level), level 2 (alarm level), and level 3 (emergency shutdown level).

12. The method for monitoring the hold-up state during wing attitude adjustment and processing according to claim 11, characterized in that: Level 0 (Normal Level): Normal Operation: All states are within the safe threshold; Response: Normal operation.

13. The method for monitoring the hold-up state during wing attitude adjustment and processing according to claim 12, characterized in that: Level 1 (Warning Level): Status Warning: A single vacuum suction cup component's Adsorption_Status_i fluctuates briefly but remains above the minimum threshold; a single force... or rate of change of force Approaching the threshold but not exceeding it; single Approaching the single-point displacement threshold; attitude parameters , , Approaching the threshold; Response: The abnormal point / parameter is highlighted on the display interface of the control system, an audible and visual prompt is issued, and the sound is different from the alarm sound. The current log is recorded. The operator intervenes to check. The control system can continue to operate, but vigilance must be maintained and the system's working status must be continuously observed.

14. The method for monitoring the hold-up state during wing attitude adjustment and processing according to claim 13, characterized in that: Level 2 (Alarm Level): Status Alarm: A single vacuum suction cup component Adsorption_Status_i remains continuously at "Vacuum suction cup component i vacuum adsorption failure"; Single force or rate of change of force Exceeding the set threshold; a single Exceeding the single-point displacement threshold; attitude parameters , , Exceeding the threshold; Response: The control system issues an audible and visual alarm, clearly indicating the fault point / type and the out-of-range parameter value on the control system's display interface. The control system automatically pauses the current automatic posture adjustment or machining program, awaiting operator confirmation. The operator must formulate a solution based on the situation.

15. The method for monitoring the hold-up state during wing attitude adjustment and processing according to claim 14, characterized in that: Level 3 (Emergency Stop Level): Adsorption Failure: Multiple vacuum suction cup components simultaneously display Adsorption_Status_i as "Vacuum suction cup component i vacuum adsorption failure"; Abnormal force: Multiple bidirectional force sensors simultaneously exceed limits, or a single force far exceeds the threshold, or A sharp increase indicates that the bidirectional force sensor has detected a severe impact force. Attitude instability: attitude parameters , , Significantly exceeding the threshold or its rate of change , Exceeding the preset emergency threshold indicates that the wing is rapidly sliding or overturning; high correlation risk: Algorithm A4 determines that adsorption failure leads to rapid changes in displacement and abnormal force. Response: Triggering the highest level, urgent audible and visual alarm, the control system immediately sends an emergency stop message to all actuators, the posture adjustment mechanism stops moving, and the machining equipment spindle stops rotating and retracts the tool. This response has the highest priority and cannot be blocked by software logic to ensure physical isolation of the risk source.

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